Multi-functional manufacturing tool

ABSTRACT

Aspects relate to systems, methods, and apparatus for a manufacturing tool. The manufacturing tool is comprised of a vacuum tool and an ultrasonic welder as a unified manufacturing tool. The manufacturing tool may be used to pick and position a manufacturing part that is then welded with the associated ultrasonic welder.

CROSS-REFERENCE TO RELATED APPLICATIONS AND CLAIM OF PRIORITY

This application is a continuation of co-pending U.S. patent applicationSer. No. 15/891,671, filed Feb. 8, 2018, titled “Multi-FunctionalManufacturing Tool,” having Attorney Docket No. NIKE.291162, which is acontinuation of U.S. patent application Ser. No. 14/816,967, filed Aug.3, 2015, titled “Multi-Functional Manufacturing Tool,” having AttorneyDocket No. NIKE.240367, which is a continuation of U.S. patentapplication Ser. No. 14/481,501, filed Sep. 9, 2014, titled“MULTI-FUNCTIONAL MANUFACTURING TOOL,” having Attorney Docket No.NIKE.182503, which is a continuation of U.S. patent application Ser. No.13/299,908, filed Nov. 18, 2011, titled “MULTI-FUNCTIONAL MANUFACTURINGTOOL,” having Attorney Docket No. NIKE.162500, each of which isincorporated herein by reference in its entirety. This application isalso related by subject matter to the following U.S. patent applicationSer. No. 13/299,856, having Attorney Docket No. NIKE.162095, titled“AUTOMATED IDENTIFICATION OF SHOE PARTS;” U.S. patent application Ser.No. 13/299,890, having Attorney Docket No. NIKE.163750, titled “HYBRIDPICKUP TOOL;” U.S. patent application Ser. No. 13/299,934, havingAttorney Docket No. NIKE.162096, titled “MANUFACTURING VACUUM TOOL;” andU.S. patent application Ser. No. 13/299,872, having Attorney Docket No.NIKE.165451, titled “AUTOMATED IDENTIFICATION AND ASSEMBLY OF SHOEPARTS,” each of which is also incorporated herein by reference in itsentirety.

BACKGROUND

Traditionally, parts used in manufacturing a product are picked up andplaced in a position for manufacturing by human hand or robotic means.However, current robotic means have not provided a level of control,dexterity, and effectiveness to be cost-effectively implemented in somemanufacturing systems.

Automated manufacturing systems that implement a variety of processeshave traditionally relied on discrete mechanisms to implement each ofthe different processes. However, having automation machinery dedicatedto a primarily-discrete task may be inefficient from a productionperspective and from a cost perspective.

SUMMARY

Aspects of the present invention relate to systems, methods andapparatus for a manufacturing tool. The manufacturing tool is comprisedof a vacuum tool and an ultrasonic welder as a unified manufacturingtool. The manufacturing tool may be used to pick and position amanufacturing part that is then welded with the associated ultrasonicwelder.

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used as an aid in determining the scope of the claimed subjectmatter.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Illustrative embodiments of the present invention are described indetail below with reference to the attached drawing figures, which areincorporated by reference herein and wherein:

FIG. 1 depicts a top-down view of an exemplary vacuum tool, inaccordance with embodiments of the present invention;

FIG. 2 depicts a front-to-back perspective cut view along a cut linethat is parallel to cutline 3-3 of the vacuum tool in FIG. 1, inaccordance with aspects of the present invention;

FIG. 3 depicts a front-to-back view of the vacuum tool along the cutline3-3 of FIG. 1, in accordance with aspects of the present invention;

FIG. 4 depicts a focused view of the vacuum generator as cut along thecutline 3-3 from FIG. 1, in accordance with aspects of the presentinvention;

FIG. 5 depicts an exemplary plate comprised of the plurality ofapertures, in accordance with aspects of the present invention;

FIGS. 6-15 depict various aperture variations in a plate, in accordancewith aspects of the present invention;

FIG. 16 depicts an exploded view of a manufacturing tool comprised of avacuum tool and an ultrasonic welder, in accordance with aspects of thepresent invention;

FIG. 17 depicts a top-down perspective view of the manufacturing toolpreviously depicted in FIG. 16, in accordance with aspects of thepresent invention;

FIG. 18 depicts a side-perspective view of the manufacturing toolpreviously depicted in FIG. 16, in accordance with aspects of thepresent invention;

FIG. 19 depicts an exploded-perspective view of a manufacturing toolcomprised of six discrete vacuum distributors, in accordance withaspects of the present invention;

FIG. 20 depicts a top-down perspective of the manufacturing toolpreviously discussed with respect to FIG. 19, in accordance withexemplary aspects of the present invention;

FIG. 21 depicts a side perspective of the manufacturing tool of FIG. 19,in accordance with aspects of the present invention;

FIG. 22 depicts a manufacturing tool comprised of a vacuum generator andan ultrasonic welder, in accordance with aspects of the presentinvention;

FIG. 23 depicts a top-down perspective of the manufacturing tool of FIG.22, in accordance with aspects of the present invention;

FIG. 24 depicts a side perspective of the manufacturing tool of FIG. 22,in accordance with aspects of the present invention;

FIG. 25 depicts a cut side perspective view of a manufacturing toolcomprised of a single aperture vacuum tool and an ultrasonic welder, inaccordance with aspects of the present invention;

FIG. 26 depicts a method for joining a plurality of manufacturing partsutilizing a manufacturing tool comprised of a vacuum tool and anultrasonic welder, in accordance with aspects of the present invention;and

FIG. 27 depicts an exemplary computing device suitable for implementingembodiments of the present invention.

DETAILED DESCRIPTION

The subject matter of embodiments of the present invention is describedwith specificity herein to meet statutory requirements. However, thedescription itself is not intended to limit the scope of this patent.Rather, the inventors have contemplated that the claimed subject mattermight also be embodied in other ways, to include different elements orcombinations of elements similar to the ones described in this document,in conjunction with other present or future technologies.

Aspects of the present invention relate to systems, methods, andapparatus for a manufacturing tool. The manufacturing tool is highlyadaptable for use with a variety of materials, a variety of shapes, avariety of part sizes, a variety of manufacturing processes, and avariety of location within an automated manufacturing system. This highlevel of adaptability provides a manufacturing tool that is a criticalcomponent in an automated manufacturing process. To accomplish this, themanufacturing tool is comprised of a vacuum tool and an ultrasonicwelder as a unified manufacturing tool that is able to be manipulatedfrom a single positional member. The manufacturing tool may be used topick and position a manufacturing part that is then welded with theassociated ultrasonic welder.

Accordingly, in one aspect, the present invention provides amanufacturing tool. The manufacturing tool is comprised of avacuum-powered part holder having a bottom surface adapted forcontacting a manufacturing part. The manufacturing tool is furthercomprised of an ultrasonic-welding horn coupled to the vacuum-poweredpart holder. The ultrasonic-welding horn is comprised of a distal endadapted for contacting the manufacturing part such that the distal endextends at least to a plane defined by the vacuum-powered part holderbottom surface.

In another aspect, the present invention provides a method of joining aplurality of manufacturing parts utilizing a manufacturing toolcomprised of a vacuum-powered part holder and an ultrasonic-weldinghorn. The method comprises positioning the manufacturing tool such thatthe vacuum-powered part holder is near a first manufacturing part. Themethod is further comprised of generating a vacuum force that istransferred through a bottom surface of the vacuum-powered part holder.The method is further comprised of temporarily maintaining the firstmanufacturing part in contact with at least a portion of thevacuum-powered part holder. Additionally, the method is comprised oftransferring the first manufacturing part to a second manufacturing partof the plurality of manufacturing parts. The method is further comprisedof releasing the first manufacturing part from the vacuum-powered partholder. Additionally, the method is comprised of positioning themanufacturing tool such that the ultrasonic-welding horn is near thefirst manufacturing part where the first manufacturing part iscontacting the second manufacturing part. The method is also comprisedof applying ultrasonic energy through the ultrasonic-welding horn. Theultrasonic energy is effective for joining the first manufacturing partwith the second manufacturing part.

A third aspect of the present invention provides a manufacturing tool.The manufacturing tool is comprised of a vacuum-powered part holder. Thevacuum-powered part holder is comprised of a plurality of vacuumdistributors. Each of the plurality of vacuum distributors is coupled toat least one other vacuum distributor of the plurality of vacuumdistributors. The vacuum-powered part holder is further comprised of aplurality of vacuum generators. Each of the plurality of vacuumgenerators is coupled to an associated vacuum distributor of theplurality of vacuum distributors. The vacuum-powered part holder isfurther comprised of a manufacturing-part-contacting surface. Themanufacturing-part-contacting surface is coupled to the plurality ofvacuum distributors. The manufacturing tool is further comprised of anultrasonic welding horn. The ultrasonic welding horn is coupled, atleast in part, to the vacuum-powered part holder such that theultrasonic welding horn and the vacuum-powered part holder are moveablein coordination.

Having briefly described an overview of embodiments of the presentinvention, a more detailed description follows.

FIG. 1 depicts a top-down view of an exemplary vacuum tool 100, inaccordance with embodiments of the present invention. In variousaspects, the vacuum tool 100 may also be referred to as a vacuum-poweredpart holder. For example, the vacuum tool 100 may be useable in anautomated (or partially automated) manufacturing process for themovement, positioning, and/or maintaining of one or more parts. Theparts manipulated by the vacuum tool 100 may be rigid, malleable, or anycombination of characteristics (e.g., porous, non-porous). In anexemplary aspect, the vacuum tool 100 is functional for picking andplacing a part constructed, at least in part, of leather, polymers,textiles, rubber, foam, mesh, and/or the like.

The material to be manipulated by a vacuum tool may be of any type. Forexample, it is contemplated that a vacuum tool described herein isadapted for manipulating (e.g., picking and placing) flat, thin, and/orlightweight parts of various shapes, materials, and other physicalcharacteristics (e.g. pattern cut textiles, non-woven materials, mesh,plastic sheeting material, foams, rubber). Therefore, unlikeindustrial-scaled vacuum tools functional for manipulating a heavy,rigid, or non-porous material, the vacuum tools provided herein are ableto effectively manipulate a variety of materials (e.g., light, porous,flexible).

The vacuum tool 100 is comprised of a vacuum generator 102. The vacuumgenerator generates a vacuum force (e.g., low pressure gradient relativeto ambient conditions). For example, the vacuum generator may utilizetraditional vacuum pumps operated by a motor (or engine). The vacuumgenerator may also utilize a venturi pump to generate a vacuum. Furtheryet, it is contemplated that an air amplifier, which is also referred toas a coanda effect pump, is also utilized to generate a vacuum force.Both the venturi pump and the coanda effect pump operate on variedprinciples of converting a pressurized gas into a vacuum force effectivefor maintaining a suction action. While the following disclosure willfocus on the venturi pump and/or the coanda effect pump, it iscontemplated that the vacuum generator may also be a mechanical vacuumthat is either local or remote (coupled by way of tubing, piping, andthe like) to the vacuum tool 100.

The vacuum tool 100 of FIG. 1 is also comprised of a vacuum distributor110. The vacuum distributor 110 distributes a vacuum force generated bythe vacuum generator 102 across a defined surface area. For example, amaterial to be manipulated by the vacuum tool 100 may be a flexiblematerial of several square inches in surface area (e.g., a leatherportion for a shoe upper). As a result of the material being at leastsemi-flexible, the vacuum force used to pick up the part may beadvantageously dispersed across a substantial area of the part. Forexample, rather than focusing a suction effect on a limited surface areaof a flexible part, which may result in bending or creasing of the partonce support underneath of the part is removed (e.g., when the part islifted), dispersing the suction effect across a greater area may inhibitan undesired bending or creasing of the part. Further, it iscontemplated that a concentrated vacuum (non-dispersed vacuum force) maydamage a part once a sufficient vacuum is applied. Therefore, in anaspect of the present invention, the vacuum force generated by thevacuum generator 102 is distributed across a larger potential surfacearea by way of the vacuum distributor 110.

In an exemplary aspect, the vacuum distributor 110 is formed from asemi-rigid to rigid material, such as metal (e.g., aluminum) orpolymers. However, other materials are contemplated. The vacuum tool 100is contemplated as being manipulated (e.g. moved/positioned) by a robot,such as a multi-axis programmable robot. As such, limitations of a robotmay be taken into consideration for the vacuum tool 100. For example,weight of the vacuum tool 100 (and/or a manufacturing tool 10 to bediscussed hereinafter) may be desired to be limited in order to limitthe potential size and/or costs associated with a manipulating robot.Utilizing weight as a limiting factor, it may be advantageous to formthe vacuum distributor in a particular manner to reduce weight whilestill achieving a desired distribution of the vacuum force.

Other consideration may be evaluated in the design and implementation ofthe vacuum tool 100. For example, a desired level of rigidity of thevacuum tool 100 may result in reinforcement portions and materialremoved portions, as will be discussed with respect to FIG. 17hereinafter, being incorporated into the vacuum tool 100.

The vacuum distributor 110 is comprised of an exterior top surface 112and an exterior side surface 116. FIG. 1 depicts a vacuum distributorwith a substantially rectangular footprint. However, it is contemplatedthat any footprint may be utilized. For example, a non-circularfootprint may be utilized. A non-circular footprint, in an exemplaryaspect, may be advantageous as providing a larger useable surface areafor manipulating a variety of part geometries. Therefore, the use of anon-circular footprint may allow for a greater percentage of thefootprint to be in contact with a manipulated part as compared to acircular footprint. Also with respect to shape of a vacuum tool 100beyond the footprint, it is contemplated, as will be discussedhereinafter, that any three-dimensional geometry may be implemented forthe vacuum distributor 110. For example, an egg-like geometry, apyramid-like geometry, a cubical-like geometry, and the like may beutilized.

The exemplary vacuum distributor 110 of FIG. 1 is comprised of theexterior top surface 112 and a plurality of exterior side surfaces 116.The vacuum distributor 110 also terminates at edges resulting in a firstside edge 128, a second parallel side edge 130, a front edge 132, and anopposite parallel back edge 134.

FIG. 1 depicts a cutline 3-3 demarking a parallel view perspective forFIG. 2. FIG. 2 depicts a front-to-back perspective cut view that isparallel along cut line 3-3 of the vacuum tool 100, in accordance withaspects of the present invention. FIG. 2 depicts, among other features,a vacuum distribution cavity 140 and a vacuum plate 150 (also sometimesreferred to as the “plate” herein). The vacuum distributor 110 and theplate 150, in combination, define a volume of space forming the vacuumdistribution cavity 140. The vacuum distribution cavity 140 is a volumeof space that allows for the unobstructed flow of gas to allow for anequalized dispersion of a vacuum force. In an exemplary aspect, the flowof gas (e.g., air) from the plate 150 to the vacuum generator 102 isfocused through the utilization of angled interior side surface(s) 118.As depicted in FIG. 2, there are four primary interior side surfaces, afirst interior side surface 120, a second interior side surface 122, athird interior side surface 124, and a fourth interior side surface 126(not shown). However, it is contemplated that other geometries may beutilized.

The interior side surfaces 118 extend from the interior top surface 114toward the plate 150. In an exemplary aspect, an obtuse angle 142 isformed between the interior top surface and the interior side surfaces118. The obtuse angle provides an air vacuum distribution effect thatreduces internal turbulence of air as it passes from the plate 150toward a vacuum aperture 138 serving the vacuum generator 102. Byangling the approach of air as it enters the vacuum aperture 138, areduced amount of material may be utilized with the vacuum distributor110 (e.g., resulting in a potential reduction in weight) and the flow ofair may be controlled through a reduction in air turbulence. An angle144 may also be defined by the intersection of the interior sidesurfaces 118 and the plate 150.

The plate 150, which will be discussed in greater detail in FIGS. 5-15hereinafter, has an interior plate surface 152 (i.e., top surface) andan opposite exterior plate surface 158 (i.e., bottom surface). Theexterior plate surface 158 is adapted for contacting a part to bemanipulated by the vacuum tool 100. For example, the plate 150 ingeneral, or the exterior plate surface 158 in particular, may be formedfrom a non-marring material. For example, aluminum or a polymer may beused to form the plate 150 in whole or in part. Further, it iscontemplated that the plate 150 is a semi-rigid or rigid structure toresist forces exerted on it from the vacuum generated by the vacuumgenerator 102. Therefore, the plate 150 may be formed of a materialhaving a sufficient thickness to resist deforming under pressurescreated by the vacuum generator 102. Additionally, it is contemplatedthat the plate 150 is formed from a material that conforms, in part, toan item to be manipulated. For example, the plate 150 may be constructedfrom a mesh-like material having a plurality of apertures defined byvoids in the mesh-like material (e.g., textile mesh, metal mesh).

When used in combination, the vacuum generator 102, the vacuumdistributor 110, and the plate 150, the vacuum tool 100 are functionalto generate a suction force that draws a material towards the exteriorplate surface 158 (also referred to as a manufacturing-part-contactingsurface) where the material is maintained against the plate 150 untilthe force applied to the material is less than a force repelling (e.g.,gravity, vacuum) the material from the plate 150. In use, the vacuumtool is therefore able to approach a part, generate a vacuum forcecapable of temporarily maintaining the part in contact with the plate150, move the vacuum tool 100 and the part to a new location, and thenallow the part to release from the vacuum tool 100 at the new position(e.g., at a new location, in contact with a new material, at a newmanufacturing process, and the like).

FIG. 3 depicts a front-to-back view of the vacuum tool 100 along thecutline 3-3 of FIG. 1, in accordance with aspects of the presentinvention. In particular, FIG. 3 provides a cut view of the vacuumgenerator 102. As will be discussed in greater detail with respect toFIG. 4, the vacuum generator 102, in the exemplary aspect, is an airamplifier utilizing a coanda effect to generate a vacuum force.

In this example, air is drawn from the exterior plate surface 158through a plurality of apertures 160 through the plate 150 to the vacuumdistribution cavity 140. The vacuum distribution cavity 140 is enclosedbetween the vacuum distributor 110 and the plate 150, such that if theplate 150 is a non-porous (i.e., lacked the plurality of apertures 160)surface, then an area of low pressure would be generated in the vacuumdistribution cavity 140 when the vacuum generator 102 is activated.However, returning to the example including the plurality of aperture160, the air is drawn into the vacuum distribution cavity 140 towardsthe vacuum aperture 138, which then allows the air to be drawn into thevacuum generator 102.

FIG. 3 identifies a zoomed view of the vacuum generator 102 depicted inFIG. 4. FIG. 4 depicts a focused view of the vacuum generator 102 as cutalong the cutline 3-3 from FIG. 1, in accordance with aspects of thepresent invention. The vacuum generator depicted in FIG. 4 is a coandaeffect (i.e., air amplifier) vacuum pump 106. The coanda effect vacuumpump injects pressurized air at an inlet 103. The inlet 103 directs thepressurized air through an internal chamber 302 to a sidewall flange304. The pressurized air, utilizing the coanda effect, curves around thesidewall flange 304 and flows along an internal sidewall 206. As aresult of the pressurized air movement, a vacuum force is generated inthe same direction as the flow of the pressurized air along the internalsidewall 306. Consequently, a direction of suction extends up throughthe vacuum aperture 138.

FIG. 5 depicts an exemplary plate 150 comprised of the plurality ofapertures 160, in accordance with aspects of the present invention.While the plate 150 is illustrated as having a rectangular footprint, aspreviously discussed, it is contemplated that any geometry may beimplemented (e.g., circular, non-circular) depending, in part, on thematerial to be manipulated, a robot controlling the vacuum tool 100,and/or components of the vacuum tool 100.

The plurality of apertures 160 may be defined, at least in part, by ageometry (e.g., circular, hatch, bulbous, rectangular), size (e.g.,diameter, radius (e.g., radius 166), area, length, width), offset (e.g.,offset 169) from elements (e.g., distance from outer edge, distance froma non-porous portion), and pitch (e.g., distance between apertures(e.g., pitch 168)). The pitch of two apertures is defined as a distancefrom a first aperture (e.g., first aperture 162) to a second aperture(e.g., second aperture 164). The pitch may be measured in a variety ofmanners. For example, the pitch may be measured from the closest twopoints of two apertures, from the surface area center of two apertures(e.g., center of circular apertures), or from a particular feature oftwo apertures.

Depending on desired characteristics of a vacuum tool, the variablesassociated with the apertures may be adjusted. For example, a non-porousmaterial of low density may not require much vacuum force to maintainthe material in contact with the vacuum tool under normal operatingconditions. However, a large porous mesh material may, on the otherhand, require a significant amount of vacuum force to maintain thematerial against the vacuum tool under normal operating conditions.Therefore, to limit the amount of energy placed into the system (e.g.,amount of pressurized air to operate a coanda effect vacuum pump,electricity to operate a mechanical vacuum pump) an optimization of theapertures may be implemented.

For example, a variable that may be sufficient for typical materialshandled in a footwear, apparel, and the like industry may include, butnot be limited to, apertures having a diameter between 0.5 and 5millimeters (mm), between 1 mm and 4 mm, between 1 mm and 3 mm, 1.5 mm,2 mm, 2.5 mm, 3 mm, and the like. However, larger and smaller diameter(or comparable surface area) apertures are contemplated. Similarly, thepitch may range between 1 mm and 8 mm, between 2 mm and 6 mm, between 2mm and 5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm, 5 mm, 5.5 mm, 6 mm, and thelike. However, larger and smaller pitch measurements are contemplated.

Additionally, it is contemplated that a variable size and a variablepitch may be implemented in aspects of the present invention. Forexample, a compound part composed of both a porous material portion anda non-porous material portion may utilize different variables toaccomplish the same level of manipulation. In this example, variablesthat lead to a reduction in necessary vacuum force in an area to becontacted by the non-porous material and variable that lead to highervacuum forces in an area to be contacted by the porous material may beimplemented. Further, a vision system or other identification system maybe used in conjunction to further ensure a proper placement of thematerial with respect to the plurality of apertures occurs.Additionally, it is contemplated that a relationship between pitch andsize may be utilized to locate the plurality of apertures. For example,a pitch from a larger sized aperture may be greater than a pitch from asmaller sized aperture (or vice versa).

An additional variable is the offset. In an exemplary aspect, the offsetis a distance of an aperture from an outside edge of the plate 150.Different apertures may have different offsets. Further different edgesmay implement different offsets. For example an offset along a frontedge may be different from an offset along a side edge. The offset mayrange from no offset to 8 mm (or more). In practice, an offset rangingfrom 1 mm to 5 mm may accomplish characteristics of exemplary aspects ofthe present invention.

The plurality of apertures 160 may be formed in the plate 150 utilizinga number of manufacturing techniques. For example apertures may bepunched, drilled, etched, carved, melted, and/or cut from the plate 150.In an exemplary embodiment, the plate 150 is formed from a material thatis responsive to laser cutting. For example polymer-based materials andsome metal-based materials may be used in conjunction with laser cuttingof the plurality of apertures.

FIGS. 6-15 provide exemplary aperture variable selections similar tothat discussed with respect to FIG. 5, in accordance with aspects of thepresent invention. The following examples are not intended to belimiting, but instead exemplary in nature. FIG. 6 depicts non-circularapertures having a first offset of 5 mm and a second offset of 8 mm anda pitch of 7 mm. FIG. 7 depicts circular apertures having an offset andpitch of 5 mm with a diameter of 2 mm. FIG. 8 depicts circular apertureshaving a diameter of 1 mm, a pitch of 2 mm, and offsets of 4 mm and 5mm. FIG. 9 depicts circular apertures having a diameter of 2 mm, a pitchof 4 mm, and offsets of 5 mm and 4 mm. FIG. 10 depicts exemplarygeometric apertures having a pitch of 4 mm and offsets of 5 mm. FIG. 11depicts circular apertures having a diameter of 1 mm, a pitch of 4 mm,and offsets of 5 mm and 4 mm. FIG. 12 depicts circular apertures havinga diameter of 1 mm, a pitch of 5 mm, and offsets of 5 mm. FIG. 13depicts circular apertures having a diameter of 1.5 mm, a pitch of 4 mm,and offsets of 5 mm and 4 mm. FIG. 14 depicts circular apertures havinga diameter of 1.5 mm, a pitch of 3 mm, and offsets of 4 mm. FIG. 15depicts circular apertures having a diameter of 2 mm, a pitch of 3 mm,and offsets of 5 mm and 4 mm. As previously discussed, it iscontemplated that shape, size, pitch, and offset may be altereduniformly or variably in any combination to achieve a desired result.

FIG. 16 depicts an exploded view of a manufacturing tool 10 comprised ofa vacuum tool 100 and an ultrasonic welder 200, in accordance withaspects of the present invention. Unlike the vacuum tool 100 discussedwith respect to FIGS. 1 and 2, the vacuum tool 100 of FIG. 16incorporates a plurality of vacuum generators 102, vacuum distributors110, and vacuum distribution cavities 140 into a unified vacuum tool100. As will be discussed hereinafter, advantages may be realized by theability to selectively activate/deactivate vacuum force in individualportions of the vacuum tool 100. Additionally, a greater control ofcontinuous vacuum force may be achieved by having segregated portions ofthe vacuum tool 100.

The manufacturing tool 10 also is comprised of a coupling member 300.The coupling member 300 is a feature of the manufacturing tool 10 (orthe vacuum tool 100 or the ultrasonic welder 200 individually) allowinga positional member 310 (not shown) to manipulate the position,attitude, and/or orientation of the manufacturing tool 10. For example,the coupling member 300 may allow for the addition of the manufacturingtool to a computer-numerically-controlled (CNC) robot that has a seriesof instructions embodied on a non-transitory computer-readable medium,that when executed by a processor and memory, cause the CNC robot toperform a series of steps. For example, the CNC robot may control thevacuum generator(s) 102, the ultrasonic welder 200, and/or the positionto which the manufacturing tool 10 is located. The coupling member 300may, therefore, allow for the temporary or permanent coupling of themanufacturing tool 10 to a positional member 310, such as a CNC robot.

As was previously discussed, aspects of the present invention may formportions of the manufacturing tool 10 with the intention of minimizingmass. As such, the plurality of vacuum distributors 110 of FIG. 16include reduced material portions 113. The reduced material portions 113eliminate portions of what could otherwise be a uniform exterior topsurface. The introduction of reduced material portions 113 reducesweight of the manufacturing tool 10 to allow for a potentially smallerpositional member 310 to be utilized, which may save on space and costs.Additional locations for reduced material portions 113 are contemplatedabout the vacuum tool 100 (e.g., side, bottom, top).

However, aspects of the present invention may desire to remain a levelof rigidity of the plurality of vacuum distributors 110 as supported bya single coupling member 300. To maintain a level of rigidity whilestill introducing the reduced material portions 113, reinforcementportions 115 may also be introduced. For example, reinforcement portions115 may extend from one vacuum distributor 110 to another vacuumdistributor 110. Further yet, it is contemplated that in aspects of thepresent invention, reinforcement portions 115 may be included proximatethe coupling member 300 for a similar rationale.

The plate 150 is separated from the plurality of vacuum distributors 110in FIG. 16 for illustrative purposes. As a result, an interior platesurface 152 is viewable. Traditionally, the interior plate surface 152is mated with a bottom portion of the plurality of vacuum distributors110, forming an air-tight bond.

The vacuum tool 100 is comprised of a plurality of vacuum generators102, vacuum distributors 110, and associated vacuum distributioncavities 140. It is contemplated that any number of each may be utilizedin a vacuum tool 100. For example, it is contemplated that 10, 8, 6, 4,2, 1, or any number of units may be combined to form a cohesive vacuumtool 100. Further, any footprint may be formed. For example, while arectangular footprint is depicted in FIG. 16, it is contemplated that asquare, triangular, circular, non-circular, part-matching shape, or thelike may instead be implemented (e.g., the units may be modular suchthat depending on the material to be manipulated additional units may beadded or removed from the vacuum tool 100). A coupling mechanism maycouple a first vacuum distributor 110 with one or more additional vacuumdistributors 110 to form the vacuum tool 100). Additionally, the size ofthe vacuum generator 102 and/or the vacuum distributor 110 may be varied(e.g., non-uniform) in various aspects. For example, in an exemplaryaspect, where a greater concentration of vacuum force is needed for aparticular application, a smaller vacuum distributor may be utilized,and where a less concentrated vacuum force is needed, a larger vacuumdistributor may be implemented.

FIGS. 16-25 depict exemplary manufacturing tools 10; however, it isunderstood that one or more components may be added or removed from eachaspect. For example, each aspect is comprised of an ultrasonic welder200 and a vacuum tool 100, but it is contemplated that the ultrasonicwelder may be eliminated all together. Similarly, it is contemplatedthat one or more additional ultrasonic welders 200 may be implemented inconjunction with the various aspects. Further, it is contemplated thatadditional features may also be incorporated. For example, visionsystems, adhesive applicators (e.g., spray, roll, hot-melt, and otherapplication methods), mechanical fastening components, pressureapplicators, curing devices (e.g., ultraviolet light, infrared light,heat applicators, and chemical applicators), lasers, heat welders, arcwelders, microwaves, other energy concentrating fastening devices, andthe like may also be incorporated in whole or in part in exemplaryaspects. For example, any of the above referenced fastening tools (e.g.,adhesive applicators, mechanical fasteners, welders, and the like) maybe used in addition to or instead of an ultrasonic welder as discussedherein. Therefore, aspects contemplate alternative fastening tools usedin conjunction with one or more vacuum tools.

The ultrasonic welder 200, in an exemplary aspect, is comprised of astack comprised of an ultrasonic welding horn 210 (may also be referredto as a sonotrode), a converter 220 (may also be referred to as apiezoelectric transducer), and a booster (not labeled). The ultrasonicwelder 200 may further be comprised of an electronic ultrasonicgenerator (may also be referred to as a power supply) and a controller.The electronic ultrasonic generator may be useable for delivering ahigh-powered alternating current signal with a frequency matching theresonance frequency of the stack (e.g., horn, converter, and booster).The controller controls the delivery of the ultrasonic energy from theultrasonic welder to one or more parts.

Within the stack, the converter converts the electrical signal receivedfrom the electronic ultrasonic generator into a mechanical vibration.The booster modifies the amplitude of the vibration from the converter.The ultrasonic welding horn applies the mechanical vibration to the oneor more parts to be welded. The ultrasonic welding horn is comprised ofa distal end 212 adapted for contacting a part. For example, the distalend 212 may be formed so as to effectively transmit the mechanicalvibration to the part while limiting the time, pressure, and/or surfacearea necessary for a particular weld. For example, the distal end may beadapted to result in a welding head spot size of a particular size forthe materials to be welded. The ultrasonic welding head spot size may bein a diameter range from 1 mm to 8 mm, or in particular at/about 4 mm,4.5 mm, 5 mm, 5.5 mm, 6 mm, and/or 6.5 mm in diameter. Further, avariety of ultrasonic welding frequencies may be implemented, such as 15kHz to 70 kHz. In an exemplary aspect, the welding frequency may be 15kHz to 35 kHz, 25 kHz to 30 kHz, 26 kHz, 27 kHz, 28 kHz, and/or 29 kHz.Various other power utilization variables may be altered. For example,power consumption may also include wattage of the ultrasonic welder. Thewattage may be adjusted based on the material, time, pressure,thickness, weld penetration, etc. In an exemplary aspect, the wattagemay be about 300 watts.

The ultrasonic welder 200 may be positioned at a plurality of locationsrelative to the vacuum tool 100. For example, the ultrasonic welder maybe located at any location along the perimeter of the vacuum tool 100.Further, it is contemplated that the ultrasonic welder 200 is offsetfrom the perimeter of the vacuum tool 100 at any distance. In anexemplary aspect, the ultrasonic welder 200 is located along theperimeter proximate the coupling member 300 to minimize movement of themanufacturing tool 10 when transitioning from vacuum to welding.Further, it is contemplated that a plurality of ultrasonic welders 200are utilized at a variety of locations about the vacuum tool 100 tofurther reduce travel time of the manufacturing tool 10. Further yet, itis contemplated that one or more ultrasonic welding tools are integratedinto the vacuum tool 100. For example, an ultrasonic welder may beintegrated at a location between two discrete vacuum distributors (e.g.,location of reduced material portions 113) such that an ultrasonicwelder 200 may extend from a top surface of the vacuum tool 100 throughto the exterior plate surface 158. Therefore, it is contemplated thatany fastening tool (such as an ultrasonic welder) may extend through thetop surface of the vacuum tool through the exterior plate 158 at anylocation, and at any orientation relative to the vacuum tool. As will bediscussed in further detail with respect to FIG. 25, a biasing mechanismmay also be implemented to allow portions of the vacuum tool 100 toapply a greater compressive force than utilized by the ultrasonic welder200 (e.g., to provide stabilization of the parts to be welded).

FIG. 17 depicts a top-down view of the manufacturing tool 10 previouslydepicted in FIG. 16, in accordance with aspects of the presentinvention. The top perspective of FIG. 17 provides an exemplary view ofa potential orientation of a plurality of vacuum distributors 110 toform a vacuum tool 100. As will be discussed hereinafter with respect toFIG. 20, various vacuum generator 102/vacuum distributor 110combinations may be selectively activated and/or deactivated tomanipulate particular parts.

FIG. 18 depicts a side-perspective view of the manufacturing tool 10previously depicted in FIG. 16, in accordance with aspects of thepresent invention. The distal end 212 of the horn 210 extends below aplane defined by the exterior plate surface 158. As a result of thedistal end 212 extending beyond the plane, the distal end 212 maycontact material without interference from the vacuum tool 100 portionof the manufacturing tool 10. However, it is contemplated that thedistal end 212 extends approximately even with the exterior platesurface 158 plane. Further, it is contemplated that the distal end 212does not extend through the plane defined by the exterior plate surface158 plane. In this example, it is contemplated that the vacuum tool 100is moveably coupled to the coupling member allowing the exterior platesurface 158 plane to move relative to the distal end 212 (e.g., biasingmechanisms, such as springs and/or pneumatics, may allow the exteriorplate surface 158 plane to move upwards once a sufficient pressure isapplied to the exterior plate surface 158). Further yet, it iscontemplated that the distal end 212 (and/or the ultrasonic welder 200in general) is oriented on the manufacturing tool 10 such that arotation about an axis by the positional member 310 alters a materialmanipulating plane from that defined by the exterior plate surface 158plane to a plane defined by the distal end 212 (e.g., the vacuum tool100 is rotated from being parallel to the materials being manipulateduntil the ultrasonic welder 200 is perpendicular (or any acceptableangle) to the material to be welded). Stated differently, it iscontemplated that instead of positioning the distal end 212 in anappropriate location utilizing X-Y-Z movements, a rotation about anX-axis, Y-axis, and/or Z-axis may be implemented to position the distalend 212.

FIG. 19 depicts an exploded-perspective view of a manufacturing tool 10comprised of six discrete vacuum distributors 110, in accordance withaspects of the present invention. The plate 150 is depicted in thisexemplary aspect as having a plurality of apertures 160 and non-apertureportions 170. The non-aperture portion 170 is a portion of the plate 150through which apertures do not extend. For example, along a segmentwhere two vacuum distributors 110 converge the plate 150 may include anon-aperture portion 170 to prevent cross feeding of vacuum between twoassociated vacuum distribution cavities 140. Further, it is contemplatedthat non-aperture portion 170 may extend along a segment in which theplate 150 is bonded (temporarily or permanently) to one or more portionsof the vacuum distributor(s) 110. Further yet, it is contemplated thatone or more non-aperture portions are integrated into the plate 150 tofurther control the placement of vacuum forces as dispersed along theexterior plate surface 158. Additionally, the non-aperture portion 170may be implemented in an area intended to be in contact with malleable(and other characteristics) portions of material that may not react wellto the application of vacuum as transferred by one or more apertures.

FIG. 20 depicts a top-down perspective of the manufacturing tool 10previously discussed with respect to FIG. 19, in accordance withexemplary aspects of the present invention. In particular six discretevacuum tool portions are identified as a first vacuum portion 402, asecond vacuum portion 404, a third vacuum portion 406, a fourth vacuumportion 408, a fifth vacuum portion 410, and a sixth vacuum portion 412.In an exemplary aspect of the present invention, one or more vacuumportions may be selectively activated and deactivated. It is understoodthat this functionality may be applied to all aspects provided herein,but are only discussed with respect to the present FIG. 20 for brevityreasons.

FIG. 21 depicts a side perspective of the manufacturing tool 10 of FIG.19, in accordance with aspects of the present invention.

FIG. 22 depicts a manufacturing tool 10 comprised of a vacuum tool 100and an ultrasonic welder 200, in accordance with aspects of the presentinvention. In particular, the vacuum tool 100 of FIG. 22 is a venturivacuum generator 104. A venturi vacuum generator, similar to a coandaeffect vacuum pump, utilizes pressurized air to generate a vacuum force.The vacuum tool 100 of FIG. 22 differs from the vacuum tool 100 of thepreviously discussed figures in that the vacuum tool 100 of FIG. 22utilizes a single aperture as opposed to a plate having a plurality ofapertures. In an exemplary aspect, the concentration of vacuum force toa single aperture may allow for a higher degree of concentrated partmanipulation. For example, small parts that may not require even a wholesingle portion of a multi-portion vacuum tool to be activated maybenefit from manipulation by the single aperture vacuum tool of FIG. 22.However, additional aspects contemplate utilizing a plate having aplurality of apertures that are not intended for contacting/covered-by ato-be manipulated part (e.g., resulting in a loss of suction that maytraditionally be undesirable).

The single aperture vacuum tool of FIG. 22 utilizes a cup 161 fortransferring the vacuum force from the venturi vacuum generator 104 to amanipulated part. The cup 161 has a bottom surface 159 that is adaptedfor contacting a part. For example, a surface finish, surface material,or size of the bottom surface may be suitable for contacting a part tobe manipulated. The bottom surface 159 may define a plane similar to theplane previously discussed as being defined from the exterior platesurface 158 of FIG. 18, for example. As such, it is contemplated thatthe distal end 212 of the ultrasonic welder 200 may be defined relativeto the plane of the bottom surface 159.

It is contemplated that the cup 161 may be adjusted based on a part tobe manipulated. For example, if a part has a certain shape, porosity,density, and/or material, then a different cup 161 may be utilized.

While two combinations of vacuum tool 100 and ultrasonic welder 200 aredepicted as forming the manufacturing tool 10 of FIG. 22, it iscontemplated that any number of features may be implemented. Forexample, a plurality of vacuum tools 100 may be utilized in conjunctionwith a single ultrasonic welder 200. Similarly, it is contemplated thata plurality of ultrasonic welders 200 may be implemented in conjunctionwith a single vacuum tool 100. Further, it is contemplated that varioustypes of vacuum tools may be implemented in conjunction. For example, amanufacturing tool 10 may be comprised of a single aperture vacuum tooland a multi-aperture vacuum tool (e.g., FIG. 1). Further yet, it iscontemplated that one or more single aperture vacuum tools are coupledwith one or more multi-aperture vacuum tools and one or more fasteningtools. As such, any number of features (e.g., tools) may be combined.

FIG. 23 depicts a top-down perspective of the manufacturing tool of FIG.22, in accordance with aspects of the present invention.

FIG. 24 depicts a side perspective of the manufacturing tool of FIG. 22,in accordance with aspects of the present invention. An offset distance169 may be adjusted for the manufacturing tool 10. The offset distance169 is a distance between the distal end 212 of the ultrasonic welder200 and the cup 161. In an exemplary aspect, the distance 169 isminimized to reduce a distance a manufacturing tool 10 travels fromplacing a part to welding the part. However, in another exemplaryaspect, the distance 169 is maintained at a sufficient distance toprevent interference in the manipulation or welding operations by theother tool portion.

FIG. 25 depicts a cut side perspective view of a manufacturing tool 10comprised of a single aperture 160 and an ultrasonic welder 200, inaccordance with aspects of the present invention. The manufacturing tool10 of FIG. 25 incorporates a moveable coupling mechanism by which theultrasonic welder 200 is allowed to slide in a direction perpendicularto a plane defined by the bottom surface 159. To accomplish thisexemplary moveable coupling, a biasing mechanism 240 is implemented toregulate an amount of pressure the distal end 212 exerts on a part,regardless of pressure being exerted in the same direction by way of thecoupling member 300. In this example a flange 214 slides in a channelthat is opposed by the biasing mechanism 240. While a spring-typeportion is illustrated as the biasing mechanism 240, it is contemplatedthat any mechanism may be implemented (e.g., gravity, counter weight,pneumatic, hydraulic, compressive, tensile, springs, and the like).

In use, it is contemplated that a force may be exerted onto a part bythe manufacturing tool 10 that is greater than necessary for the weldingof the part by the ultrasonic welder 200. As a result, the greater forcemay be effective for maintaining a part during a welding operation,while the biasing mechanism 240 may be used to apply an appropriatepressure force for a current welding operation. Further, it iscontemplated that the biasing mechanism may also be used as a dampeningmechanism to reduce impact forces experienced by one or more portions ofthe manufacturing tool 10 when contacting objects (e.g., parts, worksurface).

In use, it is contemplated that a force may be exerted onto a part bythe manufacturing tool 10 that is greater than necessary for the weldingof the part by the ultrasonic welder 200. As a result, the greater forcemay be effective for maintaining a part during a welding operation,while the biasing mechanism 240 may be used to apply an appropriatepressure force for a current welding operation. For example, it iscontemplated that the biasing mechanism 240 may allow for movement ofthe distal end 212 over a range of distances. For example, the range mayinclude 1 mm to 10 mm, 3-6 mm, and/or about 5 mm. Further, it iscontemplated that the biasing mechanism may also be used as a dampeningmechanism to reduce impact forces experienced by one or more portions ofthe manufacturing tool 10 when contacting objects (e.g., parts, worksurface).

Further yet, it is contemplated that instead of (or in addition to)utilizing a biasing mechanism, an amount of force exerted by anultrasonic welder 200 (or any fastening device) may be adjusted based onthe material to be bonded. For example, a determined percentage ofcompression may be allowed for the materials to be bonded such that anoffset height of the distal end from the plate bottom surface may beadjusted to allow for the determined level of compression for particularmaterials. In practice, highly compressible material may allow for agreater distance between a distal end of the fastening tool and thebottom surface of the vacuum plate as compared to non-highlycompressible materials that would not allow for the same amount ofcompression (measured by size or force).

Further, it is contemplated that the vacuum tool 100 is alternatively oradditionally implementing a biasing mechanism. For example, in anexemplary aspect of the present invention, the amount of pressureexerted by the vacuum tool 100 may be desired to be less than a pressureexerted by the distal end 212 on the part. As a result, a form ofbiasing mechanism 240 may be employed to controllably exert pressure onto a part by the vacuum tool 100.

An amount of force that may be exerted by a distal end having a biasingmechanism (or not having a biasing mechanism) may range from 350 gramsto 2500 grams. For example, it is contemplated that the amount of forceexerted by the distal end on a part may increase as an amount ofdistance traveled by a biasing mechanism increases. Therefore, arelationship (e.g., based on a coefficient of the biasing mechanism) maydictate an amount of pressure applied based on a distance traveled. Inan exemplary operation, such as affixing a base material, a meshmaterial, and a skin during a welding operation, about 660 grams offorce may be exerted. However, it is contemplated that more or lessforce may be utilized.

FIG. 26 depicts a method 2600 for joining a plurality of manufacturingparts utilizing a manufacturing tool 10 comprised of a vacuum tool 100and an ultrasonic welder 200, in accordance with aspects of the presentinvention. A block 2602 depicts a step of positioning the manufacturingtool 10 such that the vacuum tool 100 is proximate a first part. As usedherein, the term proximate may refer to a physical relationship thatincludes being at, on, and near. For example, the manufacturing tool maybe proximate a location when it is within a length or width of themanufacturing tool from the location. Further, it is contemplated thatthe manufacturing tool is proximate a location when the manufacturingtool is at a location defined to be within tolerance of the part to bemanipulated. The positioning of the manufacturing tool 10 may beaccomplished by a positional member 310, previously discussed.

A block 2604 depicts a step of generating a vacuum force transferredthrough a bottom surface of the vacuum tool 100. For example, one ormore of the vacuum generators 102 may be activated (e.g., as a whole,selectively) to generate a vacuum force that results in a suction effectattracting a part to the exterior plate surface 158 of FIG. 19 (or thebottom surface 159 of FIG. 22). As previously discussed, it iscontemplated that one or more vacuum portions may be selectivelyactivated (or deactivated) depending on a desired amount of vacuum forceand a desired location of vacuum force.

A block 2606 depicts a step of temporarily maintaining the first part incontact with at least a portion of the vacuum tool 100. Therefore, oncea vacuum is applied to a part and the part is attracted to the vacuumtool 100, the part is maintained in contact with the vacuum tool 100 sothat if the vacuum tool moves (or an underlying supporting surface ofthe part moves) the part will stay with the vacuum tool. The termtemporarily is utilized in this sense so as not to imply a permanent orotherwise significant bond that requires significant effort to separatethe part from the vacuum tool. Instead, the part is “temporarily”maintained for the duration that a sufficient vacuum force is applied.

A block 2608 depicts a step of transferring the first part to a secondpart. The first part may be transferred through a movement of themanufacturing tool 10. Further, it is contemplated that the transferringof the first part may be accomplished through the movement of the secondpart to the first part (e.g., an underlying conveyor system brings thesecond part towards the first part).

A block 2610 depicts a step of releasing the first part from the vacuumtool 100. For example, it is contemplated that stopping the generationof vacuum pressure by one or more vacuum generators 102 is sufficient toeffectuate the release of the first part. Further, it is contemplatedthat a burst of air that is insufficient to generate a vacuum (e.g.,insufficient to take advantage of a coanda effect) in the vacuumgenerator 102, but sufficient to cause the release of the part, may beimplemented.

Further, it is contemplated that the releasing of the first part furthercomprises activating another mechanism that opposes the vacuum pressureof the vacuum tool 100. For example, a work surface (e.g., conveyor,table top) opposite of the vacuum tool 100 may generate a vacuumpressure that counters the vacuum of the vacuum tool. This may allow forprecise placement and maintaining of the part as the vacuum tool againtransitions to a new position. The countering vacuum pressure may begenerated with a mechanical vacuum (e.g., blower) as cycling off and onmay not be needed at the same rate as the vacuum tool 100.

In an exemplary aspect of the present invention, it is contemplated thata work surface vacuum and a vacuum tool vacuum may have the followingon/off relationship for exemplary processes, as depicted in thefollowing tables. While exemplary process are indicated, it iscontemplated that additional processes may be substituted or re-arrangedwithin the process. Further, a manufacturing surface, as used herein,references a moveable article that may form a base for initiallysecuring, maintaining, aligning, or otherwise assisting in themanufacturing of a product resulting from the manipulated part(s).

Simplified Operations Table Work Surface Vacuum Tool Operation VacuumVacuum Initial state Off Off Manufacturing surface arrives On Off Robotstarts to move vacuum On Off tool for part pickup Robot reaches X %distance On On from part Robot begins moving vacuum On On tool with partto place the part Place the part On Off Affixing of part (e.g., welding)On Off End state On Off

Additional Operations Table Work Surface Vacuum Tool Operation VacuumVacuum Initial state Off Off Manufacturing surface arrives On Off Robotstarts to move vacuum On Off tool for part pickup Robot reaches X %distance On On from part Robot begins moving vacuum On On tool with partto place the part Robot reaches Y % distance Off On from themanufacturing surface Wait Z seconds Off On Place the part Off Off Robotbegins moving Off Off Robot positions welder On Off Affixing of part(e.g., welding) On Off End state On Off

Consequently, it is contemplated that any combination of work surfacevacuum and vacuum tool vacuum may be utilized to accomplish aspects ofthe present invention. In an exemplary aspect, the work surface vacuumis maintained on while a manufacturing surface is present. As a result,the work surface vacuum may utilize a mechanical vacuum generator thatmay be more efficient, but requires more start-up or wind-down time thana coanda or a venturi vacuum generator. Further, a mechanical vacuumgenerator may be able to generate a greater amount of vacuum force overa larger area than the coanda or venturi vacuum generators typicallygenerate.

A block 2612 depicts a step of positioning the manufacturing tool 10such that the distal end 212 of the ultrasonic welder 200 is proximatethe first part. In this example, it is contemplated that the first partand the second part are intended to be joined utilizing the ultrasonicwelder 200. Consequently, the ultrasonic welder is positioned in amanner to apply an ultrasonic induced bond between the first part andthe second part.

A block 2614 depicts a step of applying an ultrasonic energy through thehorn 210. The application of ultrasonic energy bonds the first and thesecond part with an ultrasonic weld.

While various steps of the method 2600 have been identified, it iscontemplated that additional or fewer steps may be implemented. Further,it is contemplated that the steps of method 2600 may be performed in anyorder and are not limited to the order presented.

FIG. 27 depicts an exemplary operating environment suitable forimplementing embodiments of the present invention, which is shown anddesignated generally as computing device 2700. Computing device 2700 isbut one example of a suitable computing environment and is not intendedto suggest any limitation as to the scope of use or functionality of theinvention. Neither should the computing device 2700 be interpreted ashaving any dependency or requirement relating to any one or combinationof modules/components illustrated.

Embodiments may be described in the general context of computer code ormachine-useable instructions, including computer-executable instructionssuch as program modules, being executed by a computer or other machine,such as a personal data assistant, mobile phone, or other handhelddevice. Generally, program modules including routines, programs,objects, modules, data structures, and the like, refer to code thatperforms particular tasks or implements particular abstract data types.Embodiments may be practiced in a variety of system configurations,including hand-held devices, consumer electronics, general-purposecomputers, specialty computing devices, etc. Embodiments may also bepracticed in distributed computing environments where tasks areperformed by remote-processing devices that are linked through acommunications network.

With continued reference to FIG. 27, computing device 2700 includes abus 2710 that directly or indirectly couples the following devices:memory 2712, one or more processors 2714, one or more presentationmodules 2716, input/output (I/O) ports 2718, I/O modules 2720, and anillustrative power supply 2722. Bus 2710 represents what may be one ormore busses (such as an address bus, data bus, or combination thereof).Although the various blocks of FIG. 27 are shown with lines for the sakeof clarity, in reality, delineating various modules is not so clear, andmetaphorically, the lines would more accurately be grey and fuzzy. Forexample, one may consider a presentation module such as a display deviceto be an I/O module. Also, processors have memory. The inventors hereofrecognize that such is the nature of the art, and reiterate that thediagram of FIG. 27 is merely illustrative of an exemplary computingdevice that can be used in connection with one or more embodiments.Distinction is not made between such categories as “workstation,”“server,” “laptop,” “hand-held device,” etc., as all are contemplatedwithin the scope of FIG. 27 and reference to “computer” or “computingdevice.”

Computing device 2700 typically includes a variety of computer-readablemedia. By way of example, and not limitation, computer-readable mediamay comprise Random Access Memory (RAM); Read Only Memory (ROM);Electronically Erasable Programmable Read Only Memory (EEPROM); flashmemory or other memory technologies; CDROM, digital versatile disks(DVD) or other optical or holographic media; magnetic cassettes,magnetic tape, magnetic disk storage or other magnetic storage devices,or any other medium that can be used to encode desired information andbe accessed by computing device 2700.

Memory 2712 includes non-transitory computer-storage media in the formof volatile and/or nonvolatile memory. The memory may be removable,non-removable, or a combination thereof. Exemplary hardware devicesinclude solid-state memory, hard drives, optical-disc drives, etc.Computing device 2700 includes one or more processors that read datafrom various entities such as memory 2712 or I/O modules 2720.Presentation module(s) 2716 present data indications to a user or otherdevice. Exemplary presentation modules include a display device,speaker, printing module, vibrating module, and the like. I/O ports 2718allow computing device 2700 to be logically coupled to other devicesincluding I/O modules 2720, some of which may be built in. Illustrativemodules include a microphone, keyboard, input device, scanner, printer,wireless device, and the like.

Additional arrangements, features, combinations, subcombination, steps,and the like are contemplated within the provided disclosure. As such,additional embodiments are inherently disclosed by the provideddiscussion.

What is claimed is:
 1. A manufacturing tool, comprising: a pickup toolcomprising a part-contacting surface having a plurality of discretepart-contacting sections; and a plurality of independently operablepickup force generators that are respectively coupled to the pluralityof discrete part-contacting sections of the pickup tool, wherein thepickup tool is adapted to provide independent activation anddeactivation of pickup force at each of the plurality of discretepart-contacting sections.
 2. The manufacturing tool of claim 1, whereinthe pickup tool is vacuum powered, and wherein the plurality of pickupforce generators comprises a plurality of vacuum force generators. 3.The manufacturing tool of claim 2, further comprising a plate coupled tothe pickup tool, wherein the part-contacting surface forms a portion ofthe plate.
 4. The manufacturing tool of claim 3, wherein the platecomprises a plurality of apertures.
 5. The manufacturing tool of claim1, further comprising a fastening device coupled to the pickup tool at alocation about a perimeter of the pickup tool.
 6. The manufacturing toolof claim 5, wherein the fastening device comprises a welder, an adhesiveapplicator, or a mechanical fastening device.
 7. The manufacturing toolof claim 6, wherein the fastening device and the pickup tool are coupledto each other in fixed relation.
 8. A manufacturing tool, comprising: apickup tool having a part-contacting surface comprising a plurality ofdiscrete part-contacting sections; a fastening device coupled to thepickup tool at a location about a perimeter of the pickup tool; and aplurality of independently operable pickup force generators coupledrespectively to the plurality of discrete part-contacting sections,wherein the pickup tool is operable to provide independent activationand deactivation of pickup force at each of the plurality of discretepart-contacting sections through operation of the plurality ofindependently operable pickup force generators.
 9. The manufacturingtool of claim 8, wherein the pickup tool is vacuum powered, and whereinthe plurality of pickup force generators comprises a plurality of vacuumforce generators.
 10. The manufacturing tool of claim 8, wherein thefastening device is a welding tool.
 11. The manufacturing tool of claim8, wherein the fastening device is an adhesive applicator.
 12. Themanufacturing tool of claim 8, wherein the fastening device is anenergy-concentrating device.
 13. The manufacturing tool of claim 8,wherein the fastening device is a mechanical fastener.
 14. Themanufacturing tool of claim 8, wherein the plurality of discretepart-contacting sections are co-planar.
 15. A manufacturing tool,comprising: a pickup tool comprising a part-contacting surface; and afastening device coupled to the pickup tool at a location about aperimeter of the pickup tool, wherein the manufacturing tool isconfigured so that when the fastening device is positioned proximate alocation at which a first manufacturing part is in contact with a secondmanufacturing part, the pickup tool is positioned away from thelocation.
 16. The manufacturing tool of claim 15, further comprising aplurality of pickup force generators coupled to the pickup tool.
 17. Themanufacturing tool of claim 16, wherein the pickup tool is operable foractivating and deactivating pickup force independently in differentsections of the part-contacting surface using the plurality of pickupforce generators.
 18. The manufacturing tool of claim 15, wherein thefastening device comprises a welding tool, an adhesive application tool,or a mechanical fastener.
 19. The manufacturing tool of claim 15,further comprising a robot arm coupled to the pickup tool.
 20. Themanufacturing tool of claim 19, further comprising a coupling memberpositioned on the pickup tool, wherein the robot arm is coupled to thepickup tool through the coupling member.